Transient Electromagnetic-Thermal Nondestructive Testing. Pulsed Eddy Current and Transient Eddy Current Thermography

347 Pages·2017·33.601 MB·English

by  Yunze He, Bin Gao, Ali Sophian and Ruizhen Yang (Auth.)

Transient Electromagnetic-
Thermal Nondestructive
Testing
Pulsed Eddy Current and Transient Eddy
Current Thermography
Yunze He
Associate Professor, College of Electrical and Information Engineering,
Hunan University, Changsha, China
College of Mechatronics Engineering and Automation,
National University of Defense Technology, Changsha, China
Bin Gao
Professor, School of Automation Engineering, University of Electronic
Science and Technology of China, Chengdu, China
Ali Sophian
Assistant Professor, Mechatronics Engineering Department,
Faculty of Engineering, International Islamic University Malaysia,
Kuala Lumpur, Kuala Lumpur, Malaysia
Ruizhen Yang
Associate Professor, Department of Civil and Architecture Engineering,
Changsha University, Changsha, China
The Boulevard, Langford Lane, Kidlington, Oxford OX5 1GB, United Kingdom
50 Hampshire Street, 5th Floor, Cambridge, MA 02139, United States
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Preface
With a growing interest in safety and quality problems in aerospace, renewable
energy, marine science, railway, traffic, civil, and other industrial fields, much
attention has been devoted to the development of reliability-based or condition-
based maintenance. Condition monitoring (CM), structural health monitoring
(SHM), and nondestructive testing (NDT) techniques are the main means to
lower the operation and maintenance (O&M) costs and improve reliability and
availability. Transient electromagnetic–thermal (EMT)-related CM, SHM, and
NDT techniques with advantages of high speed, great penetration, high sensi-
tivity, wide spectrum, low cost, and easy quantification, are widely investigated
and have become one of the most promising directions. In recent years, two
transient EMT NDT methods—pulsed eddy current (PEC) and transient eddy
current thermography (TECT)—have been the research hotspots. For example,
in the Elsevier ScienceDirect database, PEC has been on a steady increasing
phase in the past 10 years and TECT has been growing rapidly since 2011.
Unfortunately, there are only a few books on PEC and TECT published in Eng-
lish, which hinders the spread and development of the technology and related
research. In addition, there are more and more bilingual courses in many uni-
versities in China and non-English-speaking countries that would benefit from
the availability of such a book. Many undergraduate and postgraduate students,
as well as scientists and engineers, need a suitable book for their study and re-
search on EMT NDT. Therefore, it is thought that it is the right time to publish
a relevant book to meet the demand of readers.
This book is intended to solve several challenges in the physical principles,
methods, techniques, and applications of PEC and TECT. Theoretically, mul-
tiphysics fields including EM induction, eddy current distribution, induction
heating, heat conduction, thermal wave propagation, temperature field distribu-
tion, and infrared radiation are studied for defect evaluation and quantification;
lateral heat conduction is used to detect parallel cracks; longitudinal heat con-
duction is used to detect deep defects, which are beyond the skin depth; ther-
mal wave propagation is analyzed for phase-based defect quantification, and
the physical–mathematical model is investigated to improve detection sensitiv-
ity and quantitative analysis. Methodologically, various EMT NDT techniques
like eddy current pulse thermography (ECPT), eddy current step thermography
(ECST), eddy current pulse phase thermography (ECPPT), and pulsed induc-
tive thermal wave radar (PI-TWR) are investigated. Time-domain, frequency-
domain, and logarithm-domain defect evaluation methods are described and
xi
xii Preface
analyzed; advanced algorithms, such as principal components analysis (PCA),
independent components analysis (ICA), support vector machine (SVM), and
multidimensional tensor decomposition are used, and image reconstruction and
enhancement is used to improve detectability. In view of applications, material
property variations including conductivity, permeability, and lift-off are evaluat-
ed; experimental studies for real damages including corrosion in steel, stress in
aluminum, impact and delamination in carbon fiber reinforced polymer (CFRP)
laminates, and RCF cracks in rail are abundant. The book is expected to fill the
gap in the literature and provide a relatively comprehensive coverage of PEC
and TECT, giving the readers detailed information in related theories, methods,
and applications, and benefit readers in both academia and industry.
Chapter 1 introduces the classification of NDT and the classification of tran-
sient EMT NDT techniques. The book mainly consists of three parts. Part I is
related to PEC. In Chapter 2, a PEC technique where a magnetic sensor is used
for sensing the magnetic field is introduced. The usages of signal processing
and feature extraction using PCA and wavelets on PEC signals are also pre-
sented. In Chapter 3, the influences of material properties on PEC responses
are investigated and normalization technique is used to reduce the lift-off effect.
Subsequently, two time-domain features representing electrical conductivity
and magnetic permeability are extracted. These features are utilized to measure
stress in aluminum alloys, to detect defects in honeycomb sandwich structures,
to evaluate low-energy impact defects in CFRP, and to characterize atmospheric
corrosion on steel. In Chapter 4, the directional PEC probe design providing
uniform eddy current is presented. The PEC feature extraction techniques are
then studied in both time and frequency domains. PEC frequency response op-
timization is investigated and used in combination with PCA to eliminate the
lift-off effect and interlayer air gap and to classify defects in multilayer struc-
tures. The optimized SVM is used to build the classifier model and predict the
types of defects.
Part II, which includes Chapters 5–12, is related to TECT and its methods for
defect evaluation and characterization. In Chapter 5, basic concepts and classifi-
cations for active thermography and eddy current thermography are introduced.
Chapter 6 is focused on defect evaluation based on longitudinal and lateral heat
conduction of ECPT. Subsurface defects, parallel cracks, and natural oblique
cracks in rail are evaluated. Chapter 7 is focused on ECST. Two characteristic
features representing separation time were extracted from temperature respons-
es and their monotonic relationships with defect depth were obtained for sub-
surface quantification. Chapter 8 introduces ECPPT for metal materials through
numerical and experimental studies. Two characteristic features, namely blind
frequency and minimum phase, were extracted from differential phase spectra.
Based on their linear relationships with defect depth, both features can be used
to measure defect depth. This chapter also experimentally demonstrates the ad-
vantages of phase information to reduce or enlarge the effect of surface emis-
sivity variation. Chapter 9 presents volume heating thermography (VHT) and
Preface xiii
inside heating thermography (IHT) for advanced composite materials through
these electromagnetic excitations. Several specific VHT/IHT methods have
been developed in the forms of both (square) pulse and step analysis in the time
domain and phase analysis in the frequency domain. Chapter 10 presents eddy
current volume heating thermography (ECVHT) and phase analysis for delami-
nation and impact inspection in CFRP. Chapter 11 presents PI-TWR by intro-
ducing cross correlation (CC) matched filtering in ECPT. The results illustrate
a significant improvement in the dynamic range, depth resolution, emissivity
variation reduction, and detectability of subsurface defects and inside delamina-
tion. Chapter 12 proposes through coating imaging (TCI) based on ECPPT. The
experimental results illustrate that ECPPT has a greater potential for corrosion
detection, sizing, and monitoring than laser profilometry, PEC, and microwave
waveguide. Finally, power function is suitable for demonstrating development
of early stage (in 6 months) marine atmospheric corrosion like it does for long-
term corrosion.
Part III, including Chapters 13–16, is related to the physical–mathemati-
cal model-based ECPT for defect evaluation. Chapter 13 constructs a physi-
cal–mathematical time-dependent partition model to analyze the whole thermal
transient process and considers characteristic times for separating Joule heating
and thermal diffusion into four different stages. Chapter 14 proposes an unsu-
pervised method for defect diagnosis with ECPT. The proposed method is fully
automated and does not require manual selection of the specific thermal frame
images for defect diagnosis by the user. The core of the method is a hybrid of
a physics-based inductive thermal mechanism with a signal processing-based
pattern extraction algorithm using sparse greedy based principal component
analysis (SGPCA). Chapter 15 develops a physics-based multidimensional spa-
tial–transient–stage tensor model to describe the thermooptical flow (TOF) pat-
tern for evaluating contact fatigue damage in a helical gear. It indicates that the
proposed methods are effective tools for gear inspection and fatigue evaluation.
In Chapter 16, we generate a physics–mathematical modeling and mining route
in the spatial-, time-, frequency-, and sparse-pattern domains. This is a sig-
nificant step toward realizing the deeper insight in ECPT and automatic defect
identification. This renders ECPT a promising candidate for the highly efficient
and yet flexible nondestructive testing and evaluation (NDT&E) technique.
Dr. Yunze He
Associate Professor, College of Electrical and Information Engineering,
Hunan University, Changsha, China;
College of Mechatronics Engineering and Automation,
National University of Defense Technology, Changsha, China
Dr. Bin Gao
Professor, School of Automation Engineering,
University of Electronic Science and Technology of China, Chengdu, China
xiv Preface
Dr. Ali Sophian
Assistant Professor, Mechatronics Engineering Department,
Faculty of Engineering, International Islamic University Malaysia,
Kuala Lumpur, Selangor, Malaysia
Dr. Ruizhen Yang
Associate Professor, Department of Civil and Architecture Engineering,
Changsha University, Changsha, China
October 2016
Acknowledgments
The authors work was supported in part by the National Natural Science
Foundation of China under grants 61501483, 61171134, F011404, 51377015,
61401071, U1430115, 51408071, and 61527803; in part by the EU FP7 through
Health Monitoring of Offshore Wind Farms (www.hemow.eu) under grant
269202; and in part by the Engineering and Physical Sciences Research Council
(EPSRC) of the United Kingdom through Future Reliable Renewable Energy
Conversion Systems & Networks: A Collaborative UK–China Project under
grant EP/F06151X/1. The authors would also like to thank TWI Ltd., the Uni-
versity of Huddersfield and Newcastle University, United Kingdom for sponsor-
ing Dr. Ali Sophian’s PhD research and study. The authors also thank ALSTOM
and Prof. Grimberg in the National Institute of Research and Development for
Technical Physics, Romania, for providing the experimental CFRP samples.
The authors would like to thank Prof. Gui Yun Tian at the School of
Automation Engineering, University of Electronic Science and Technology of
China, Chengdu, China, and the School of Electrical and Electronic Engineering,
Newcastle University, Newcastle Upon Tyne, United Kingdom, and Dr. W.L.
Woo at the School of Electrical and Electronic Engineering, Newcastle Uni-
versity, United Kingdom for their guidance and leadership in their studies and
academic careers. Dr. Yunze He would like to thank Prof. Feilu Luo and Prof.
Mengchun Pan at the College of Mechatronics Engineering and Automation,
National University of Defense Technology, Changsha, China for supervision
in Mr. Yunze He’s MA and PhD programs. Dr. Ali Sophian would like to again
thank Dr. John Rudlin of TWI Ltd. and Prof. David Taylor at the University of
Huddersfield for their supervision, guidance, and support during his PhD study.
The authors would like to thank their colleagues: Dr. John Wilson, Dr. Liang
Cheng, Dr. Hong Zhang, Prof. Xianzhang Zuo, Dr. Libing Bai, Prof. Aijun
Yin, Dr. Jianping Peng, Dr. Omar Bouzid, Dr. Abdul Qubaa, Dr. Kongjing Li,
Dr. Yunlai Gao, Dr. Yizhe Wang and all at Newcastle University; Dr. Ying Tang,
Dr. Yuhua Zhang, Dr. Xiangchao Hu, Dr. Junzhe Gao, Dr. Bo Liu and all at the
National University of Defense Technology, who have provided fruitful discus-
sions and advice on pulsed eddy current testing.
The authors are also grateful to the China Scholarship Council for sponsor-
ing Dr. Yunze He to Newcastle University, United Kingdom and Dr. Ruizhen
Yang to the University of British Columbia, Canada for joint study. The trans-
lation, polishing, and publication of the book are partly supported by Talent
xv
xvi Acknowledgments
Development Special Funding of Changsha City, Hunan Province, China. The
authors also thank editors in Elsevier (Dr. Simon Tian, Glyn Jones, Naomi
Robertson, and Susan Li) and the National Defense Industry Press, China
(Ms. Junyin Xin and Xinjuan Zhang) for their help and advice.
The authors’ deepest thanks go to their parents and families, for always sup-
porting and encouraging their research and study.
Yunze He, Bin Gao, Ali Sophian, Ruizhen Yang
October 2016
Abbreviations
ACFM Alternating current field measurement
ADC Analog-to-digital converter
AHT Abnormal heating thermography
APG Accelerated proximal gradient
BOB Bottom of bottom
BOT Bottom of top
BPT Burst phase thermography
BSS Blind source separation
CC Cross correlation
CCMF Cross correlation matched filtering
CFRP Carbon fiber reinforced plastic
CM Condition monitoring
DAC Different absolute contrast
DAQ Data acquisition
DF Diff frequency to zero
DFT Discrete Fourier transform
DL Digital level
DWT Discrete wavelength transform
EC Eddy current
ECLT Eddy current lock-in thermography
ECPPT Eddy current pulsed phase thermography
ECPT Eddy current pulsed thermography
ECSPPT Eddy current square pulsed phase thermography
ECSPT Eddy current square pulsed thermography
ECST Eddy current step thermography
ECT Eddy current testing or eddy current thermography
ECTRT Eddy current time-resolved thermography
ECVHT Eddy current volume heating thermography
EDM Electrical discharge machine
EIS Electrochemical impedance spectroscopy
EMAT Electromagnetic acoustic transducers
EMNDT Electromagnetic nondestructive testing
EMT Electromagnetic–thermal
EVD Eigenvalue decomposition
FD Fault diagnosis
FEM Finite element modeling
FFT Fast Fourier transform
FMT Frequency modulated thermography
FN False negative
xvii
xviii Abbreviations
FP False positive
GFRP Glass fiber reinforced plastic
GMR Giant magnetoresistive
IC Independent components
ICA Independent component analysis
IHT Inside heating thermography
IR Infrared
LHC Lateral heat conduction
LLT Laser lock-in thermography
LOI Lift-off point of intersection or lift-off invariance
LST Line scanning thermography
LT Lock-in thermography
MAE Magnetoacoustic emission
MBN Magnetic Barkhausen noise
MCMC Markov chain Monte Carlo
MFL Magnetic flux leakage
MP Matching pursuit
MT Modulated thermography
MUT Materials under test
MWT Microwave thermography
NC Normalized contrast
NDE Nondestructive evaluation
NDT Nondestructive testing
NDT&E Nondestructive testing and evaluation
NMF Nonnegative matrix factorization
OF Optical flow
O&M Operations and maintenance
OMP Orthogonal matching pursuit
PC Principal components
PCA Principal component analysis
PEC Pulsed eddy current
PI-TWR Pulsed inductive thermal-wave radar
POD Probability of detection
PPI Preprocessed image
PPMM Physics–mathematical pattern modeling and mining
PPT Pulsed phase thermography
PSO Particle swarm optimization
PT Penetration testing or pulsed thermography
PTFE Polytetrafluoroethylene
QEC Quantitative error curve
RBF Radial basis function
RCF Rolling contact fatigue
RFID Radio frequency identification
ROC Receiver operating characteristic
SeHT Selectively heating thermography
SFPM Spatial–frequency pattern mining
SGPCA Sparse greedy based principal components analysis
SHM Structural health monitoring